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MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
MB07: Advanced Simulation for Design and Optimization
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MB07: Advanced Simulation for Design and Optimization

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Do you want to show a customer how your machine or equipment fits their application and performance demands or do you want to better understand how potential changes will impact capacity and …

Do you want to show a customer how your machine or equipment fits their application and performance demands or do you want to better understand how potential changes will impact capacity and throughput? Arena® Advanced Simulation tools enable you to build custom working models that show a prospective client how your
machine or equipment would meet their application requirements and performance expectations. This session will focus on how Advanced Simulation tools and services from Rockwell Automation can be used as a part of the sales process, capacity and performance configuration, machine and equipment design, and performance optimization.

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  • 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Advanced Simulation for Design and Optimization Is It Part of Your Competitive Edge?
  • 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Case Study – Pallet Stretch Wrapping
  • 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Case Study  Soft Drink Pallet Wrapping Machines  Plant Layout:  Case packer line  5 Palletizer Lines feeding 2 Stretch Wrappers  Challenge:  Increased load pushing pallet wrapping machines to limits 5
  • 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Case Study  Questions:  Can the two existing Stretch Wrappers keep up with increased load?  Is an additional stretch wrapping machine required?  What directional feeding rules will ensure that palletizer lines don’t back up?  What directional feeding rules will maintain smooth, continuous operations? 6
  • 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Addressing the Challenge 7  Built a simulation model of the process using Arena simulation software  Identified variability/uncertainty around key process parameters  Package types  Pallet creation times  Pallet wrapping times  Forklift speeds  Stretch wrapper failure/downtime modes and frequencies  Run simulation scenarios to test alternate designs  Revised Feeding Rules  Addition of 3rd stretch wrapper
  • 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Visualizing the Operation 8
  • 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Variability Considerations (Input) 9 Time to create pallet (TRI dist) Min Mode Max Time to wrap pallet ("stop to start") in minutes WyardDelay 923CDelay 320Delay 923ADelay FS800Delay Wyard 90 137 165 Muller 808 46 44 923C - 12 Packs 102 196 235 Muller 606 44 44 44 41 320 - 6 Packs 133 784 940 923A - Cube 79 157 188 3 0 FS800 240 343 411 East West Choose the package coming off the Wyard Forklift Speed in ft/min 250 250 9 70% % eff Stretchwrapper Failure Modes mean time betw een failure (minutes) Uptime Downtime Uptime Downtime Muller 808 - West 112 8 235 5 Choose the package coming off the FS800 Muller 606 - East 232 8 235 5 1 70% % eff What is your can line efficiency 75% % eff East West Switch at M12 (1=West, 2=East, 3=Auto) Break Film Change
  • 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Arena Simulation Results  Developed New Palletizer Feeding Rules to Eliminate Backlogs  Line 1: Feed Left Only  Line 2: Feed Left or Right  Lines 3,4 & 5 Feed Right Only  3rd Stretch Wrapper Not Required:  $150K Capex avoidance  Reduced long-term system maintenance costs 10
  • 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 11 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Discrete Event Simulation Modeling events that occur over time, including all variability and system interactions, to predict the future performance of complex business processes and to assess the overall system capabilities under virtually any set of “what if” conditions. 12 What is Discrete Event Simulation? Implement Here Test Here Simulation and Your Company  Understand how complex systems work  Answer critical “What if..?” questions  Visualize operations  Insurance policy for major decisions  Completely risk-free environment
  • 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Why Simulation? 13  Optimize designs/layouts  Get it right the first time  Visualize problems and solutions  Communicate ideas, gain consensus, destroy myths!  Avoid wasteful spending  Differentiate from competition
  • 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Advantages of Simulation  Compare alternative designs  Incorporate system variability  Include system interactions  Observe complex systems over time  Animation communicates ideas  Understand bottlenecks  Low risk/high return Excel Simulation Enhance Competitive Advantage
  • 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Benefits from a typical Arena simulation project are usually 10-20x the initial investment within four to six months of initial use.
  • 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 16 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Arena Simulation Software 17  World’s leading discrete event simulation software  Used by majority of Fortune 100 companies  Capable of modeling virtually any system or process  Easy-to-use flowchart modeling methodology  Large university install base  35-year track record of success and proven results
  • 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Arena Models All Business Processes Supply Chain Management Customer Relationship Management Suppliers Customers Supplier Management Customer Service Warehousing Inventory Manufacturing Processes Distribution Logistics Business Processes - Who? - When? - How much? - How? - Inventory-control Mechanisms - Tactical Planning - Stock Levels - Delivery Mechanisms - Shipment Methods - Site Planning - Dispatching Rules - Front Office - Order Fulfillment - Workflow - Internal Processes - Multi-channel Contact - Staffing - Outsourcing - Call Routing - Job Routing - Factory Flow - Capacity Planning - Staffing - IT and ERP
  • 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 19 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 20 Agenda Driving Competitive Advantage Demonstration Why Arena Simulation Overview Introduction
  • 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Benefits for OEMs 21  Validation of system design  Incorporate variability, uncertainty and constraints into design  Quantitative comparison of alternatives  Demonstrate design to customers  Optimize/enhance equipment performance  Value-add service/expertise to customers  Extension of simulation models to real-time applications
  • 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Support from Rockwell Automation 22  Training courses  Bi-monthly courses in Austin, TX  On-site, customized courses  Technical Support  M-F, 9-5 (Eastern Time)  Phone or e-mail  Consulting Services  Project assistance  Turn-key projects
  • 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Need Additional Information? 23  Sales  Sean Connors  smconnors@ra.rockwell.com  +1 (512) 680-3473  Technical Support  arena-support@ra.rockwell.com  +1 (440) 646-6789  www.ArenaSimulation.com
  • 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Summary 24  Optimize designs and equipment performance  Visualize problems and solutions  Communicate ideas, gain consensus, destroy myths!  Avoid wasteful spending  Get it right the first time  Differentiate from competition
  • 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Questions?
  • 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank You!

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